Guide transition device and method

ABSTRACT

A guide transition device including a light source designed to generate a light beam, a light input port on a first plane and coupled to receive the light beam from the light source, a light output port on a second plane different than the first plane, the light output port designed to couple a received light beam to output equipment and plane shifting apparatus coupled to receive the light beam from the light input port on the first plane and to shift or transfer the light beam to the second plane. The plane shifting apparatus is coupled to transfer the light beam to the light output port on the second plane.

FIELD OF THE INVENTION

This invention relates to guiding light from semiconductor lasers inlayers of polymers on a semiconductor substrate and more particularly totransitioning light from one layer to another to reduce opticalcross-talk and other interference.

BACKGROUND OF THE INVENTION

Polymer modulators driven by semiconductor lasers are a popularapparatus for modulating a light beam. In a copending applicationentitled “Polymer Modulator and Laser Integrated on a Common Platformand Method”, filed Aug. 31, 2017, with application Ser. No. 15/692,080,and incorporated herein by reference, the modulator and laser areintegrated on a common platform, such as an InP chip or substrate.

One problem with including various light devices, such as lightgenerating devices and light using devices, on a common plane or levelis that light can couple between devices along unintended paths, such asthrough reflections or tunneling, to cause optical cross-talk and otherinterference. Further, light coupling between devices and between inputsand outputs can be inefficient with lost light traveling through theoptical system to cause optical cross-talk and other interference.

It would be highly advantageous, therefore, to remedy the foregoing andother deficiencies inherent in the prior art.

Accordingly, it is an object of the present invention to provide a newand improved guide transition device for efficiently coupling lightbetween devices and to output apparatus.

It is another object of the present invention to provide a new andimproved guide transition device for coupling light from one planes toanother plane to reduce optical cross-talk and other interference.

SUMMARY OF THE INVENTION

Briefly to achieve the desired objects and advantages of the instantinvention in accordance with a preferred embodiment a guide transitiondevice is provided that includes a light source designed to generate alight beam, a light input port on a first plane and coupled to receivethe light beam from the light source, and a light output port on asecond plane different than the first plane. The light output port isdesigned to couple a received light beam to output equipment. The guidetransition device further includes plane shifting apparatus coupled toreceive the light beam from the light input port on the first plane andto shift or transfer the light beam to the second plane. The planeshifting apparatus is further coupled to transfer the light beam to thelight output port on the second plane.

To further achieve the desired objects and advantages of the presentinvention a specific embodiment of a guide transition device comprises aplatform including a semiconductor waveguide defining a light input portfor receiving a light beam. The semiconductor laser is positioned on afirst plane and one end of the semiconductor waveguide is formed into anangled surface. A polymer planarizing layer deposited on the platform inabutting engagement with the angled surface provides a first angulardeflection surface. A lower polymer cladding layer deposited on thepolymer planarizing layer, a polymer core deposited on the lower polymercladding layer, and an upper polymer cladding layer deposited on thecore and lower polymer cladding layer form a polymer waveguide on asecond plane different than the first plane with a first end defining alight output port. Portions of the lower polymer cladding layer, thecore, and the upper polymer cladding layer are removed to form a secondangular deflection surface at an end of the polymer waveguide oppositethe first end. The first angular deflection surface and the secondangular deflection surface have compatible angles so that a light beamdirected into the light input port defined by the semiconductorwaveguide on the first plane is deflected into the core of the polymerwaveguide on the second plane.

To further achieve the desired objects and advantages of the presentinvention a specific method of fabricating a guide transition deviceincludes the step of providing a platform including a semiconductorwaveguide defining a light input port for receiving a light beam withthe semiconductor laser positioned on a first plane. The method includesthe steps of forming one end of the semiconductor waveguide into anangled surface and depositing a polymer planarizing layer on theplatform in abutting engagement with the angled surface to provide afirst angular deflection surface. The method further includes the stepsof depositing a lower polymer cladding layer on the polymer planarizinglayer, depositing a polymer core on the lower polymer cladding layer,and depositing an upper polymer cladding layer on the core and lowerpolymer cladding layer. The lower polymer cladding layer, the polymercore, and the upper polymer cladding layer form a polymer waveguide on asecond plane different than the first plane with a first end defining alight output port. The method further includes the steps of removingportions of the lower polymer cladding layer, the core, and the upperpolymer cladding layer to form a second angular deflection surface at anend of the polymer waveguide opposite the first end. The first angulardeflection surface and the second angular deflection surface havecompatible angles so that a light beam directed into the light inputport defined by the semiconductor waveguide on the first plane isdeflected into the core of the polymer waveguide on the second plane.

BRIEF DESCRIPTION OF THE DRAWINGS

Specific objects and advantages of the invention will become readilyapparent to those skilled in the art from the following detaileddescription of a preferred embodiment thereof, taken in conjunction withthe drawings in which:

FIG. 1 is a top view of a PSM (phase shift modulation) layout with asingle laser source divided into four inputs for four differentmodulators using a guide transition device (GTD) to couple the fourinputs into four waveguides and then out to four fiber cables, accordingto the present invention;

FIG. 2 is a top view of a WDM (wavelength division multiplexing) layoutwith four different wavelength lasers coupled by four GTDs and thenmux'd into one waveguide and out to a fiber cable, according to thepresent invention;

FIG. 3A is a cross-sectional view of an example of a narrow spot designfor a guide transition device in accordance with the present invention;

FIG. 3B is a top view of the guide transition device illustrated in FIG.3A;

FIG. 4A is a cross-sectional view of another example of a narrow spotdesign for a guide transition device in accordance with the presentinvention;

FIG. 4B is a top view of the guide transition device illustrated in FIG.4A;

FIGS. 5A through 5I illustrate steps in the fabrication of the narrowspot design guide transition device of FIG. 3A in accordance with thepresent invention;

FIG. 6A is a cross-sectional view of an example of a large spot designfor a guide transition device in accordance with the present invention;

FIG. 6B is a top view of the guide transition device illustrated in FIG.6A;

FIG. 7A is a cross-sectional view of another example of a large spotdesign for a guide transition device in accordance with the presentinvention;

FIG. 7B is a top view of the guide transition device illustrated in FIG.7A, showing a Mach-Zehnder modulator implemented between taper regions,according to the present invention;

FIGS. 8A through 8I illustrate steps in the fabrication of the largespot design guide transition device of either FIG. 6A or FIG. 7A inaccordance with the present invention;

FIG. 9 is a cross-sectional view of a waveguide illustrating protectionlayers above and below the core; and

FIG. 10 is a cross-sectional view of a waveguide illustrating anotherarrangement of protection layers above and below the core.

DETAILED DESCRIPTION OF THE DRAWINGS

A primary object of the present invention is to provide a new andimproved guide transition device fabricated in light guiding apparatusincluding a substrate and multiple polymer layers. The guide transitiondevice is designed to efficiently couple light from one layer or planeof the light guiding apparatus to another layer or plane of the lightguiding apparatus to reduce optical cross-talk and other interference.In the preferred embodiment, the light guiding apparatus includes alight input port coupled to receive light from a light source, such as asemiconductor laser or waveguides fabricated to guide light from alaser, positioned on a first plane, plane shifting apparatus coupled toreceive the light from the light input port and to shift or transfer thelight to another or second layer or plane, above or below the firstlayer or plane, and a light output port on the second layer or planecoupled to the plane shifting apparatus and designed to couple lightfrom the plane shifting apparatus to some type of output equipment, suchas an optical fiber, waveguide, etc. The plane shifting apparatus canbe, for example, an angular deflection surface, explained in more detailbelow, or gratings.

Turning to FIG. 1, an example of phase shift modulation (PSM) apparatus10 incorporating a guide transition device 12, in accordance with thepresent invention, is illustrated. In this example, guide transitiondevice 12 receives light from a source 14, such as a semiconductorlaser, on a first level and shifts or transfers the light to a secondlevel. On the second level guide transition device 12 couples the lightto a first waveguide 15 that is split into two waveguides using asplitter with each of the two waveguides being split for a total of fourwaveguides. Each of the four waveguides is then coupled to or passesthrough a modulator 16, 17, 18, and 19, respectively, and extends to theedge of the chip ready to launch the phase modulated light into fiberoptics or the like. Modulators 16, 17, 18, and 19 can alternatively beintensity modulators, for example, a Mach-Zehnder modulator, adirectional-coupler modulator, a polarization modulator, etc. In suchembodiments, the modulator becomes an intensity modulator (IM); the useof the term “PSM” herein is generic and includes all of the above listedmodulators.

Turning to FIG. 2, an example of wavelength division multiplexing (WDM)apparatus 20 incorporating four guide transition devices 21, 22, 23, and24, in accordance with the present invention, is illustrated. Guidetransition device 21 couples light from a light source 25, such as asemiconductor laser, on a first level, to a polymer waveguide andmodulator 26 on a second, different level. Similarly, guide transitiondevice 22 couples light from a light source 27 to a polymer waveguideand modulator 28 on a second, different level, guide transition device23 couples light from a light source 29 to a polymer waveguide andmodulator 30 on a second, different level, and guide transition device24 couples light from a light source 31 to a polymer waveguide andmodulator 32 on a second, different level. Light from polymer waveguidesand modulators 26, 28, 30, and 32 is coupled to a multiplexer 34 wherethe four inputs are multiplexed down to a single output fiber 35.Examples of devices that can be used for multiplexer 34 include amultimode modulator interferometer (MMI), thin film filters, Eschellegratings, arrayed waveguide gratings (AWG), or the like. Modulators 26,28, 30, and 32 can be phase, polarization, or intensity modulators (seeabove).

Thus, in PSM apparatus 10 a single light source is coupled through asingle guide transition device into four fibers and four modulators toproduce four different phase (or intensity) signals. In WDM apparatus20, four lasers operating at four different wavelengths, couple via fourguide transition devices into four modulators/waveguides that are muxedinto a single output fiber. In all instances the guide transitiondevices shift or transfer the light from the level or plane in which thelight source lies, to another plane or level containing waveguides andmodulators to essentially separate or insulate the waveguides andmodulators from any stray light produced by the light source.

Referring now to FIGS. 3A and 3B, a guide transition device 40 isprovided as an example of a guide transition device that could be usedin either of PSM apparatus 10 or WDM apparatus 20 or any other lightguiding apparatus. In this specific example, a monolithic semiconductorlaser 42 and a polymer waveguide modulator 44 are included in device 40and fabricated on a substrate 41, which in this preferred embodiment ismonolithic InP but can be other semiconductors or metals, such assilicon, silicon carbide, GaN, GaAs, InSb, metals, sapphire, etc.Monolithic laser 42 can be a distributed feedback (DFB) laser, aFabry-Perot (FB) laser, a distributed Bragg reflector (DBR) laser, atunable laser, VCSEL (Vertical Cavity Surface Emitting Laser) or anyother type of semiconductor laser. Laser 42 includes an outputsemiconductor waveguide 43 (with a core 43 a) which is angularly etchedat 46 and most of the epi material is removed from substrate 41 beyondangular etch 46 to minimize the problems of trying to deposit polymersin a trench-like structure. A lower polymer layer 48 is deposited onsubstrate 41 to planarize substrate 41 and to form an angular deflectionsurface 47 with the angular etch 46. Alternatively, an insulating oxideor nitride could be deposited on substrate 41 to planarize substrate 41and to form an angular deflection surface 47 with the angular etch 46.These techniques are also compatible with use of a lower electrode toenable vertical poling in the polymer waveguide.

A relatively thick lower cladding layer 49 is deposited on the uppersurfaces of laser 42 and lower polymer layer 48, a core polymer isdeposited on the upper surface of lower cladding layer 49 and etched toform a waveguide core 50, and an upper polymer cladding layer 51 isdeposited around waveguide core 50 to form a polymer waveguide 52. Insome instances, it may be desirable to deposit an anti-reflective (AR)coating 54 on the upper surface of laser 42 prior to depositing lowercladding layer 49 to reduce or remove any reflections at the abuttingsurfaces. Usually the AR coating can be completed via dielectricdeposition using CVD, PECVD, sputtering, ebeam, etc. Materials for thedielectric coating can be, for example, oxides, nitrides, andcombinations thereof deposited with a thickness for anti-reflectionproperties. Also, a relatively thick lower cladding layer 49 isdeposited to minimize light leakage from polymer core 50 to substrate41.

Lower cladding layer 49, core 50, and upper polymer cladding layer 51(i.e. polymer waveguide 52) are etched at an angle and through to theupper surface of laser 42 to form an angular deflection surface 56. Inthis example, angular deflection surface 47 and angular deflectionsurface 56 are included in the plane shifting apparatus that shiftslight from the laser source on one plane to waveguide 52 and the lightoutput on a different plane. The angle of surface 56 is selected to becompatible with the etched angle of angular deflection surface 47,resulting in high optical coupling into waveguide 52. In this preferredembodiment, deflection surface 47 deflects the received light beam at anangle of approximately 90 degrees (plus or minus 10 degrees) anddeflection surface 56 is compatible to deflect the received light beaminto waveguide core 50 parallel to the second plane. The semiconductorguide width (i.e. the output of laser 42 adjacent angular deflectionsurface 47) can also be adjusted relative to the width of polymerwaveguide 52 to enhance coupling using mode-size conversion designs. Tofurther enhance reflection at angular deflection surface 56, a highreflective coating 57 can be deposited on the outer surface of angulardeflection surface 56. In this specific example, polymer waveguidemodulator 44 is formed in waveguide 52 between angular deflectionsurface 56 and taper 58 of core 50. Modulator 44 can be for example, aMach-Zehnder modulator, an intensity or phase modulator, etc.

A typical semiconductor laser will put-out a spot (beam area) with 35degrees vertical divergence and 15 degrees horizontal divergence whichmeans the laser beam diverges hugely. As explained, in the guidetransition device 40 the laser beam is coupled into waveguide 52 whichkeeps the beam from diverging any more. Unfortunately, the dimensions ofwaveguide 52 are relatively tiny. Waveguide 52 will couple the spot(reflected laser beam) into the small dimensions of waveguide 52 and forguide transition device 40 to operate better between the planes orlevels, there must be as much alignment tolerance (e.g. at the output ofwaveguide 52) as possible. Better alignment tolerance is achieved inguide transition device 40 by reducing core 50 of waveguide 52 to ataper 58 adjacent the output, which produces a large spot size,represented by broken lines 59, at the output edge of waveguide 52 forcoupling into external equipment, such as fibers or the like. The largespot size 59 at the output makes the alignment of guide transitiondevice 40 with exterior equipment easier and more manufacturable.

Referring additionally to FIGS. 4A and 4B, a guide transition device 40′is provided as another example of a guide transition device that couldbe used in either of PSM apparatus 10 or WDM apparatus 20 or any otherlight guiding apparatus. Components of guide transition device 40′ thatare the same as components of guide transition device 40 of FIGS. 3A and3B are designated with a similar number and a prime (′) is added toindicate the different embodiment. Guide transition device 40′ issimilar in all respects to guide transition device 40, except that core43 a′ is tapered (designated 45 in FIG. 4B) as it approaches angulardeflection surface 47′ to increase the spot size of light deflected intocore 50′ of waveguide 52′. The large spot size 59 at the output of guide43′ makes the alignment of the planes easier and more manufacturable.

Referring now to FIGS. 5A through 5I, some sequential steps in apreferred process for fabricating guide transition devices, such asguide transition device 40, is illustrated. For convenience ofunderstanding, the same numbers used in FIGS. 3A and 3B will be used inFIGS. 5A through 5I to designate the same components. Referringspecifically to FIG. 5A, monolithic semiconductor laser 42 is fabricatedon substrate 41, which in this preferred embodiment is InP but may beany semiconductor material. Monolithic laser 42 can be a distributedfeedback (DFB) laser, a Fabry-Perot (FB) laser, a distributed Braggreflector (DBR) laser, a tunable laser, VCSEL (Vertical Cavity SurfaceEmitting Laser) or any other type of semiconductor laser. Laser 42includes an output waveguide 43 (with a core 43 a) which is angularlyetched at 46 and most of the epi material is removed from substrate 41beyond angular etch 46 to minimize the problems of trying to depositpolymers in a trench-like structure. In some instances, it may bedesirable to deposit an anti-reflective coating 54 on the upper surfaceof output waveguide 43 to reduce or remove any reflections at thesurface. Coating 54 can be deposited as described above.

Referring additionally to FIG. 5B, lower polymer layer 48 is depositedon substrate 41 to planarize substrate 41 and to form an angulardeflection surface 47 with the angular etch 46. In this preferredembodiment, lower polymer layer 48 is a spin-on coat or it could bedeposited by CVD. After deposition, lower polymer layer 48 is etchedback using an oxygen based process to planarize lower polymer layer 48.

Referring additionally to FIG. 5C, a relatively thick lower claddinglayer 49 is deposited on the upper surfaces of laser 42 and lowerpolymer layer 48. In this preferred embodiment, lower cladding layer 49is a spin-on coat or it could be deposited by CVD. After deposition,lower cladding layer 49 is etched back using an oxygen based process toplanarize lower cladding layer 49 and achieve a desired thickness. Toreduce core 50 of waveguide 52 to taper 58 adjacent the output,photolithography masking and etching are used to define 2-dimensionaltaper 58 in the upper surface of lower cladding layer 49, as illustratedin FIG. 5D.

Referring additionally to FIG. 5E, a layer of polymer material isdeposited on the upper surface of lower cladding layer 49 and shapedinto waveguide core 50, including 2-dimensional taper 58, usingphotolithography masking and etching. Referring additionally to FIG. 5F,upper cladding layer 51 is deposited on lower cladding layer 49 andsurrounding core 50. In this preferred embodiment, upper cladding layer51 is deposited using spin-on deposition techniques and the conformitywith core 50 planarizes waveguide 52.

Turning to FIG. 5G, lower cladding layer 49, core 50, and upper polymercladding layer 51 (i.e. polymer waveguide 52) are etched at an angle andthrough to the upper surface of laser 42 to form an angular deflectionsurface 56. The angle of surface 56 is selected to be compatible withthe etched angle of angular deflection surface 47, resulting in highoptical coupling into waveguide 52. Preferably, an HR (highreflectivity) reflector 57 is deposited on the outer surface of angulardeflection surface 56, as illustrated in FIG. 5H. HR reflector 57 canbe, for example, an HR coating, dielectric material, metallic, orcombinations thereof. Metallic electrodes, designated 60 in FIG. 5I, areadded for electrical connections to modulator 44.

Referring now to FIGS. 6A and 6B, a guide transition device 100 isprovided as an example of a guide transition device that could be usedin either of PSM apparatus 10 or WDM apparatus 20 or any other lightguiding apparatus. In this specific example, a monolithic semiconductorlaser 102 and a polymer waveguide modulator 104 are included in device100 and fabricated on a substrate 101, which in this preferredembodiment is monolithic InP but can be other semiconductors or metals,such as silicon, silicon carbide, GaN, GaAs, InP, metals, sapphire, etc.Monolithic laser 102 can be a distributed feedback (DFB) laser, aFabry-Perot (FB) laser, a distributed Bragg reflector (DBR) laser, atunable laser, VCSEL (Vertical Cavity Surface Emitting Laser) or anyother type of semiconductor laser. Laser 102 includes an outputsemiconductor waveguide 103 (with a core 103 a) which is angularlyetched at 106 and most of the epi material is removed from substrate 101beyond angular etch 106 to minimize the problems of trying to depositpolymers in a trench-like structure. A lower polymer layer 108 isdeposited on substrate 101 to planarize substrate 101 and to form anangular deflection surface 107 with the angular etch 106. Alternatively,an insulating oxide or nitride could be deposited on substrate 101 toplanarize substrate 101 and to form an angular deflection surface 107with the angular etch 106. These techniques are also compatible with useof a lower electrode to enable vertical poling in the polymer waveguide.In some instances, it may be desirable to deposit an anti-reflective(AR) coating 105 on the upper surface of laser 102 prior to depositing alower cladding layer 109 to reduce or remove any reflections at theabutting surfaces. Usually the AR coating can be completed viadielectric deposition using CVD, PECVD, sputtering, ebeam, etc.Materials for the dielectric coating can be, for example, oxides,nitrides, and combinations thereof deposited with a thickness foranti-reflection properties.

A relatively thick lower cladding layer 109 is deposited on the uppersurfaces of laser 102 and lower polymer layer 108, a core polymer isdeposited on the upper surface of lower cladding layer 109 and etched toform a waveguide core 110, and an upper polymer cladding layer 111 isdeposited around waveguide core 110 to form a polymer waveguide 112. Insome instances, it may be desirable to deposit an anti-reflectivecoating 114 on the upper surface of laser 102 prior to depositing lowercladding layer 109 to reduce or remove any reflections at the abuttingsurfaces. Also, a relatively thick lower cladding layer 109 is depositedto minimize light leakage from polymer core 110 to substrate 101.

Lower cladding layer 109, core 110, and upper polymer cladding layer 111(i.e. polymer waveguide 112) are etched at an angle and through to theupper surface of laser 102 to form an angular deflection surface 116. Inthis example, angular deflection surface 107 and angular deflectionsurface 116 are included in the plane shifting apparatus that shiftslight from the laser source on one plane to waveguide 112 and the lightoutput on a different plane. The angle of surface 116 is selected to becompatible with the etched angle of angular deflection surface 107,resulting in high optical coupling into waveguide 112. To furtherenhance reflection at angular deflection surface 116, a high reflectivecoating 117 can be deposited on the outer surface of angular deflectionsurface 116.

For guide transition device 100 to operate most efficiently between theplanes or levels and to make the alignment of guide transition device100 easier and more manufacturable, there must be as much alignmenttolerance as possible between the layers or planes. Better alignmenttolerance is achieved in guide transition device 100 by reducing core103 a of laser output waveguide 103 to a taper 120 adjacent angular etch106, which produces s large spot size, represented by broken lines 122,at angular deflection surface 107. The large spot size 122 deflected byangular deflection surface 107 onto angular deflection surface 116 atthe input of waveguide 112 makes the alignment of guide transitiondevice 100 easier and more manufacturable.

To further enhance alignment tolerance in guide transition device 100,waveguide core 110 includes a taper 124 in which the dimensions of core110 are reduced as core 110 progresses from a midpoint to adjacentangular deflection surface 116. Taper 124, in conjunction with the largespot size deflected onto angular deflection surface 116, substantiallyincreases alignment tolerance between the planes. Also, better alignmenttolerance is achieved in guide transition device 100 by reducing core110 of waveguide 112 to a taper 126 adjacent the output, which producesa large spot size, represented by broken lines 128, at the output edgeof waveguide 112 for coupling into external equipment, such as fibers orthe like. The large spot size 126 at the output makes the alignment ofguide transition device 100 with exterior equipment easier and moremanufacturable. In this specific example, polymer waveguide modulator104 is formed in waveguide 112 between taper 124 and taper 126 of core110. Modulator 104 can be for example, a Mach-Zehnder modulator, anintensity, polarization, or phase modulator, etc.

Referring additionally to FIGS. 7A and 7B, a guide transition device100′ is provided as another example of a guide transition device thatcould be used in either of PSM apparatus 10 or WDM apparatus 20 or anyother light guiding apparatus. Components of guide transition device100′ that are the same as components of guide transition device 100 ofFIGS. 6A and 6B are designated with a similar number and a prime (′) isadded to indicate the different embodiment. Guide transition device 100′is similar in all respects to guide transition device 100, except thatmodulator 104 is a Mach-Zehnder modulator with core tapers 124′ and 126′designed much smaller to accommodate Mach-Zehnder modulator 104′therebetween. The purpose of the examples illustrated in FIGS. 6A, 6B.7A, and 7B are to illustrate specifically how various modulators can beincorporated into a guide transition device in accordance with thepresent invention.

Referring now to FIGS. 8A through 8I, some sequential steps in apreferred process for fabricating guide transition devices, such asguide transition device 100, is illustrated. For convenience ofunderstanding, the same numbers used in FIGS. 6A and 6B will be used inFIGS. 8A through 8I to designate the same components. Referringspecifically to FIG. 8A, monolithic semiconductor laser 102 isfabricated on substrate 101, which in this preferred embodiment is InPbut may be any semiconductor material. Monolithic laser 102 can be adistributed feedback (DFB) laser, a Fabry-Perot (FB) laser, adistributed Bragg reflector (DBR) laser, a tunable laser, VCSEL(Vertical Cavity Surface Emitting Laser) or any other type ofsemiconductor laser. Laser 102 includes an output waveguide 103 (with acore 103 a) which is angularly etched at 106 and most of the epimaterial is removed from substrate 101 beyond angular etch 106 tominimize the problems of trying to deposit polymers in a trench-likestructure. In some instances, it may be desirable to deposit ananti-reflective coating 114 on the upper surface of laser outputwaveguide 103 to reduce or remove any reflections at the surface.

Referring additionally to FIG. 8B, lower polymer layer 108 is depositedon substrate 101 to planarize substrate 101 and to form an angulardeflection surface 107 with the angular etch 106. In this preferredembodiment, lower polymer layer 108 is a spin-on coat or it could bedeposited by CVD. After deposition, lower polymer layer 108 is etchedback using an oxygen based process to planarize lower polymer layer 108.In some instances, it may be desirable to deposit an anti-reflectivecoating 105 on the upper surface of output waveguide 102 to reduce orremove any reflections at the surface. Coating 105 can be deposited asdescribed above.

Referring additionally to FIG. 8C, a relatively thick lower claddinglayer 109 is deposited on the upper surfaces of laser 102 and lowerpolymer layer 108. In this preferred embodiment, lower cladding layer109 is a spin-on coat or it could be deposited by CVD. After deposition,lower cladding layer 109 is etched back using an oxygen based process toplanarize lower cladding layer 109 and achieve a desired thickness. Toreduce core 110 of waveguide 112 to tapers 124 and 126, photolithographymasking and etching are used to define 2-dimensional tapers 124 and 126in the upper surface of lower cladding layer 49, as illustrated in FIG.8D.

Referring additionally to FIG. 8E, a layer of polymer material isdeposited on the upper surface of lower cladding layer 109 and shapedinto waveguide core 110, including 2-dimensional tapers 124 and 126,using photolithography masking and etching. Referring additionally toFIG. 8F, upper cladding layer 111 is deposited on lower cladding layer109 and surrounding core 110. In this preferred embodiment, uppercladding layer 111 is deposited using spin-on deposition techniques andthe conformity with core 110 planarizes waveguide 112.

Turning to FIG. 8G, lower cladding layer 109, core 110, and upperpolymer cladding layer 111 (i.e. polymer waveguide 112) are etched at anangle and through to the upper surface of laser 102 to form an angulardeflection surface 116. The angle of surface 116 is selected to becompatible with the etched angle of angular deflection surface 107,resulting in high optical coupling into waveguide 112. Preferably, an HR(high reflectivity) reflector 117 is deposited on the outer surface ofangular deflection surface 116, as illustrated in FIG. 8H. HR reflector117 can be, for example, an HR coating, dielectric material, metallic,or combinations thereof. Metallic electrodes, designated 130 in FIG. 8I,are added for electrical connections to modulator 104.

Referring to FIG. 9, a cross-sectional view of a waveguide 150, such aswaveguide 44 in FIG. 3A or waveguide 104 in FIG. 6A, is illustrated witha first protection layer 152 sandwiched between a lower polymer claddinglayer 154 and a polymer core 156. A second protection layer 158 issandwiched between polymer core 156 and an upper polymer cladding layer160. Protection layers, such as protection layers 152 and 158 are usefulduring fabrication processes and need to be matched optically(refractive index) as well as chemically so that layers of polymers canbe deposited without interference either by light or chemical reaction,because in the preferred embodiment the polymers are liquid that isspun-on and then polled and cured. It will be understood that whilesingle protective layers 152 and 158 are illustrated for this example,additional layers might be included to increase protection and/or forother purposes.

Referring to FIG. 10, a cross-sectional view of another waveguide 170,is illustrated in which protective layers are formed to not only providethe functions described above but also aid in substantially reducingstray light loss. In this example, a series of four protective coatings,designated 174, are positioned between a bottom cladding layer 172 and acore 176. Series of layers 174 are specifically selected with differentcoefficients of reflection so as to operate as distributed Braggreflectors (DBR) or mirrors that reflect stray light back into core 176.Similarly, a second series of protective layers, designated 178 arepositioned on the upper surface of core 176. Series of layers 178 arespecifically selected with different coefficients of reflection so as tooperate as distributed Bragg reflectors (DBR) or mirrors that reflectstray light back into core 176.

Thus, a new and improved guide transition device for efficientlycoupling light between devices and to output apparatus is disclosed. Thenew and improved guide transition device is specifically designed toreduce optical cross-talk and other interference. Also, the new andimproved guide transition device can be specifically designed tosubstantially increase alignment tolerance between the planes and betteralignment tolerance with external equipment, such as fibers or the like.

Various changes and modifications to the embodiments herein chosen forpurposes of illustration will readily occur to those skilled in the art.To the extent that such modifications and variations do not depart fromthe spirit of the invention, they are intended to be included within thescope thereof which is assessed only by a fair interpretation of thefollowing claims.

Having fully described the invention in such clear and concise terms asto enable those skilled in the art to understand and practice the same,the invention claimed is:

1. A guide transition device comprising: a light source designed togenerate a light beam; a light input port on a first plane, the lightinput port being coupled to receive the light beam from the lightsource; a light output port on a second plane different than the firstplane, the light output port designed to couple a received light beam tooutput equipment; and plane shifting apparatus coupled to receive thelight beam from the light input port on the first plane and to shift ortransfer the light beam to the second plane, the plane shiftingapparatus being coupled to transfer the light beam to the light outputport on the second plane.
 2. The guide transition device as claimed inclaim 1 wherein the light source includes a semiconductor laser.
 3. Theguide transition device as claimed in claim 1 wherein the semiconductorlaser includes one of a distributed feedback laser, a Fabry-Perot laser,a distributed Bragg reflector laser, a VCSEL, or a tunable laser.
 4. Theguide transition device as claimed in claim 1 wherein the light outputport is defined by a polymer waveguide positioned on the second plane,the polymer waveguide receiving at a first end the beam of light fromthe plane shifting apparatus and defining the light output port at asecond end.
 5. The guide transition device as claimed in claim 4 whereinthe polymer waveguide further defines a polymer modulator between thefirst end and the second end.
 6. The guide transition device as claimedin claim 5 wherein the polymer modulator includes one of a Mach-Zehndermodulator, an intensity modulator, polarization modulator, or a phasemodulator.
 7. The guide transition device as claimed in claim 1 whereinthe plane shifting apparatus includes one of one or more angulardeflection surfaces or gratings.
 8. The guide transition device asclaimed in claim 7 wherein the plane shifting apparatus includes a firstangular deflection surface positioned on the first plane and a secondangular deflection surface positioned on the second plane, the firstangular deflection surface positioned to receive the light beam from thelight input port and to deflect the light beam to the second angulardeflection surface, and the second angular deflection surface positionedto deflect the light beam into light communication with the output port.9. The guide transition device as claimed in claim 8 wherein the firstangular deflection surface is positioned at an angle that deflects thereceived light beam approximately ninety degrees and the second angulardeflection surface is positioned at an angle that is compatible with theangle of the first deflection surface to direct the light beam parallelto the second plane.
 10. The guide transition device as claimed in claim8 wherein the first angular deflection surface is formed by a firstangled surface of a semiconductor layer and a second angled surface of apolymer layer, the first angled surface and the second angled surfacebeing in abutting engagement to form a reflective surface.
 11. The guidetransition device as claimed in claim 10 wherein the semiconductor layerfurther includes a semiconductor waveguide with a core, thesemiconductor waveguide being fabricated to form the first angledsurface.
 12. The guide transition device as claimed in claim 11 whereinthe semiconductor waveguide core is tapered in cross-sectional area froma midpoint to adjacent the first angled surface.
 13. The guidetransition device as claimed in claim 8 and further including a polymerwaveguide positioned on the second plane and further positioned tocouple the light beam from the second deflection surface to the lightoutput port on the second plane.
 14. The guide transition device asclaimed in claim 13 wherein the polymer waveguide includes a lowercladding layer, a core, and an upper cladding layer, a first end of thelower cladding layer, the core, and the upper cladding layer being cutat an angle to define the second angular deflection surface, and asecond end of the lower cladding layer, the core, and the upper claddinglayer defining the light output port.
 15. The guide transition device asclaimed in claim 14 wherein the core of the polymer waveguide is taperedin cross-sectional area from a midpoint to adjacent the light outputport.
 16. The guide transition device as claimed in claim 14 wherein thecore of the polymer waveguide is tapered in cross-sectional area from amidpoint to a waveguide edge adjacent the cut second end of the lowercladding layer, the core, and the upper cladding layer defining thesecond angular deflection surface.
 17. The guide transition device asclaimed in claim 13 wherein the polymer waveguide includes at least oneprotection layer between the lower cladding layer and the core, and atleast one protection layer between the upper cladding layer and thecore.
 18. A guide transition device comprising: a platform including asemiconductor waveguide defining a light input port for receiving alight beam, the semiconductor laser being positioned on a first plane;one end of the semiconductor waveguide being formed into an angledsurface; a polymer planarizing layer deposited on the platform inabutting engagement with the angled surface to provide a first angulardeflection surface; a lower polymer cladding layer on the polymerplanarizing layer, a polymer core deposited on the lower polymercladding layer, and an upper polymer cladding layer deposited on thecore and lower polymer cladding layer, the lower polymer cladding layer,the polymer core, and the upper polymer cladding layer forming a polymerwaveguide on a second plane different than the first plane with a firstend defining a light output port; and portions of the lower polymercladding layer, the core, and the upper polymer cladding layer removedto form a second angular deflection surface at an end of the polymerwaveguide opposite the first end, the first angular deflection surfaceand the second angular deflection surface having compatible angles sothat a light beam directed into the light input port defined by thesemiconductor waveguide on the first plane is deflected into the core ofthe polymer waveguide on the second plane.
 19. A method of fabricating aguide transition device comprising the steps of: providing a platformincluding a semiconductor waveguide defining a light input port forreceiving a light beam, the semiconductor laser being positioned on afirst plane; forming one end of the semiconductor waveguide into anangled surface; depositing a polymer planarizing layer on the platformin abutting engagement with the angled surface to provide a firstangular deflection surface; depositing a lower polymer cladding layer onthe polymer planarizing layer, depositing a polymer core on the lowerpolymer cladding layer, and depositing an upper polymer cladding layeron the core and lower polymer cladding layer, the lower polymer claddinglayer, the polymer core, and the upper polymer cladding layer forming apolymer waveguide on a second plane different than the first plane witha first end defining a light output port; and removing portions of thelower polymer cladding layer, the core, and the upper polymer claddinglayer to form a second angular deflection surface at an end of thepolymer waveguide opposite the first end, the first angular deflectionsurface and the second angular deflection surface having compatibleangles so that a light beam directed into the light input port definedby the semiconductor waveguide on the first plane is deflected into thecore of the polymer waveguide on the second plane.
 20. The method asclaimed in claim 19 wherein the step of depositing the lower polymercladding layer includes the step of depositing by one of spin-on-coatingor CVD.
 21. The method as claimed in claim 20 wherein the step ofdepositing the lower polymer cladding layer further includes the step ofphotolithographic masking and etching the lower polymer cladding layerto define a taper in the core adjacent the first end defining the lightoutput port.
 22. The method as claimed in claim 20 wherein the step ofdepositing the lower polymer cladding layer further includes the step ofphotolithographic masking and etching the lower polymer cladding layerto define a taper in the core adjacent the second angular deflectionsurface.
 23. The method as claimed in claim 20 wherein the steps ofdepositing the lower polymer cladding layer on the polymer planarizinglayer, depositing the polymer core on the lower polymer cladding layer,and depositing the upper polymer cladding layer on the core and lowerpolymer cladding layer, further includes the steps of depositing atleast one protection layer between the lower polymer cladding layer andthe core and depositing at least one protection layer between the upperpolymer cladding layer and the core.